Floorboard having locking mechanisms comprising polymer

ABSTRACT

This present disclosure relates to a floorboard comprising a main panel and a polymer frame that is continuous and comprises along two opposing edges a first locking mechanism and along the other two opposing edges a second locking mechanism different from the first one.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present disclosure claims the benefit of priority from U.S. provisional application No. 62/516,243 filed on Jun. 7, 2017 and from Canadian application no. 2,979,897 filed on Sep. 19, 2017. These documents are hereby incorporated by reference in their entirety.

FIELD OF THE DISCLOSURE

The present disclosure relates to a floorboard. More particularly, the present disclosure relates to a floorboard with a continuous polymer frame. The present disclosure also relates to a floorboard with a polymer coating.

BACKGROUND OF THE DISCLOSURE

Traditional floorboards connect through locking mechanisms on the edges of each floorboard. The locking mechanism and main body of the floorboard are often made with the same material and usually from one piece of flat board, such that extensive machining is required to manufacture the locking mechanism. The process of manufacture not only requires special machineries and labourious handling, it generates large amount of material waste since significant parts of the edges of the flat board need to be removed.

In addition, the material constituting the edges of the floorboard such as solid wood, compound wood, particle board, laminated wood and bamboo, is often soft and moisture sensitive, such that the connecting edges cannot withstand the constant forces exercised on the locking mechanism through daily wear, and the expansion and contraction associated with seasonal change in moisture and temperature. This leads to cracks and warping of the floor.

SUMMARY OF THE DISCLOSURE

It would be desirable to develop a floorboard that has connecting edges that are strong enough to withstand the pressure exercised on the floorboard. Preferably, the process of manufacturing the floorboard would eliminate the extensive machining and waste of material. Further, the floorboard should maintain the usual esthetics required of a floor decoration.

To achieve the abovementioned object, the present disclosure comprises a floorboard having a continuous plastic frame or a polymer coating surrounding the periphery of the main panel of the floorboard.

In one embodiment, there is provided the floorboard comprising a main panel and a continuous polymer frame perimeterial to the main panel. In another embodiment, the polymer frame comprises a first locking mechanism disposed on two opposing edges of the main panel, and a second locking mechanism different from the first locking mechanism disposed on two other opposing edges of the main panel.

In another embodiment, the polymer frame offers a more durable connecting means than the traditional wood-based material. In another embodiment, the process of manufacturing the floorboard in the present disclosure lessens the generation of waste material compared to the traditional floorboard manufacturing. In another embodiment, the floorboard is more resistant to deformation due to changes in moisture level and temperature.

In another embodiment, the polymer frame further comprises recesses along at least two of the four edges of the floorboard. In another embodiment, the recesses on the polymer frame help reduce cracking and deformation of polymer frame and the floorboard.

In one embodiment, the main panel itself comprises a locking mechanism along two opposing edges of the main panel. In this embodiment, the main panel comprises a polymer coating that coats at least the locking mechanism.

In another embodiment, the polymer coating offers reinforcement to the existing locking mechanism.

BRIEF DESCRIPTION OF THE DRAWINGS

The following drawings represent examples that are presented in a non-limitative manner.

FIG. 1 illustrates a top view of a floorboard with a polymer fame according to one embodiment of the present disclosure;

FIG. 2 illustrates a side view of the floorboard of FIG. 1, showing the male counterpart of a first locking mechanism on a long edge as well as a side view of a male portion of a second locking mechanism on the left short edge and its female counterpart on the right short edge;

FIG. 3 illustrates another side view of the floorboard of FIG. 1, showing the male part of the second mechanism on the short edge as well as a side view of a male portion of the first mechanism on the left long edge and its female counterpart on the right long edge;

FIG. 4 illustrates an exploded view of the floorboard according to another embodiment of the present disclosure, where there is a balance sheet underneath the main panel, a decorative layer on top of the main panel and a protective layer as the topmost layer;

FIG. 5 illustrates a sectional side view of the floorboard of FIG. 1, showing in proximity the male portion of the second locking mechanism on one floorboard and the female counterpart of the second locking mechanism on another floorboard, as well as a side view part of the male portion of the first locking mechanism along the long edge of the floorboard;

FIG. 6 illustrates a sectional side view of the floorboard of FIG. 1, showing in proximity the male portion of the first locking mechanism on one floorboard and the female counterpart of the first locking mechanism on another floorboard, as well as a side view part of the male portion of the second locking mechanism along the short edge of the floorboard;

FIG. 7A illustrates a cross section of a side view of the floorboard according to another embodiment of the present disclosure, showing a polymer coating around the main panel at least on the locking mechanism;

FIG. 7B illustrates a cross section of a side view of the floorboard according to another embodiment of the present disclosure, showing a polymer coating around the main panel at least on the locking mechanism;

FIG. 8 illustrates an enlarged partial perspective view of a part of the floorboard of FIG. 1, showing, at right, the female portion of the first locking mechanism along the long edge of the floorboard and showing, in front, the male portion of the second locking mechanism along the short edge of the floorboard;

FIG. 9 illustrates an enlarged partial perspective view of a part of the floorboard of FIG. 1 showing, in front, the female portion of the first locking mechanism along the long edge of the floorboard and showing the male portion of the second locking mechanism along the short edge of the floorboard;

FIG. 10 illustrates an enlarged partial side view of a part of the floorboard of FIG. 1 according to one embodiment of the present disclosure, showing the male portion of the second locking mechanism along the short edge of the floorboard;

FIG. 11 illustrates a top view of the floorboard according to another embodiment of the present disclosure, showing the floorboard with polymer frame and recesses along the edges of the polymer frame;

FIG. 12 illustrates a side view of the floorboard of FIG. 11, showing the recesses along a long edge of the polymer frame of the floorboard;

FIG. 13 illustrates a side view of the floorboard of FIG. 11, showing the recesses on the polymer frame along a short edge of the floorboard carrying the male portion of a drop and lock mechanism;

FIG. 14 illustrates a side view of the floorboard of FIG. 11, showing the recesses on the polymer frame along the short edge of the floorboard opposing the edge shown in FIG. 13 carrying the female portion of a drop and lock mechanism;

FIG. 15 is a perspective view of the floorboard of FIG. 11, showing, at left, the recesses along the short edge of the floorboard carrying the male portion of a drop and lock mechanism, and at right showing the recesses along the long edge of the floorboard carrying the female portion of a tongue and groove mechanism

FIG. 16 is a perspective view of the floorboard of FIG. 11, showing, at left, the recesses along the long edge of the floorboard carrying the female portion of a tongue and groove mechanism, and at right showing the recesses along the short edge of the floorboard carrying the female portion of a drop and lock mechanism;

FIG. 17 is a perspective view of the floorboard of FIG. 11, showing, at left, the recesses along the long edge of the floorboard carrying the male portion of a tongue and groove, and at right showing the recesses along the short edge of the floorboard carrying the male portion of a drop and lock mechanism;

FIG. 18 is a partial perspective view of the floorboard of FIG. 11, showing, in front, the recesses along the long edge of the floorboard carrying the male portion of a tongue and groove, and at right showing the recesses along the short edge of the floorboard carrying the male portion of a drop and lock mechanism;

FIG. 19 illustrates a perspective bottom view of a part of the floorboard of FIG. 11, showing in front, the recesses along the long edge of the floorboard carrying the female portion of a tongue and groove, and at right showing the recesses along the short edge of the floorboard carrying the female portion of a drop and lock mechanism; and

FIG. 20 illustrates a perspective view of a part of the floorboard of FIG. 11, showing at left, the short edge of the floorboard carrying the female portion of a drop and lock mechanism, and at right showing the recesses along the long edge of the floorboard carrying the male portion of a tongue and groove mechanism.

DETAILED DESCRIPTION OF THE DISCLOSURE

The following examples are presented in a non-limitative manner.

The expression “tongue and groove” used herein refers to a method of joining two objects together by means of fitting a tongue on one board into a matching indentation or groove of another board. For example, such a joining can be done by inclining the boards with respect to one another and sliding the tongue of one board into the groove of the other board. Then, when removing inclination between the two boards so that they are both at same angle or both lying flat on a surface, the two boards are locked with respect to one another, thereby preventing sliding or movement of the boards with respect to one another.

The expression “drop and lock” used herein refers to a method of joining two boards together by means of fitting at least one flange or block protruding from an extension of one board into a matching groove extending from the other object. For example, a “drop and lock” mechanism contrasts with a sliding locking mechanism (such as tongue and groove mechanism) since the “drop and lock” method does not involve sliding one board into another board. For example, once a flange or block of a board is dropped into another board, the boards are not prevented from sliding with respect to one another.

The expression “wood-based material” used herein includes but is not limited to materials comprising solid wood, compound wood, cellulose, fine wood particles, cellulose filaments, wood fibers, pulp and paper sludge, and bamboo.

The expression “consisting essentially of”, as used herein, is intended to specify the presence of the stated features, elements, components, groups, integers, and/or steps as well as those that do not materially affect the basic and novel characteristic(s) of features, elements, components, groups, integers, and/or steps.

Terms of degree such as “about” and “approximately” as used herein mean a reasonable amount of deviation of the modified term such that the end result is not significantly changed. These terms of degree should be construed as including a deviation of at least ±10% of the modified term if this deviation would not negate the meaning of the word it modifies.

For example, the floorboard can further comprise a balance sheet underneath the main panel. For example, the balance sheet can comprise wood particles, wood fibers and/or a polymer. For example the balance sheet can comprise a kraft paper optionally with melamine. For example, the balance paper can have a weight of about 60 to about 120 g or about 90 to about 100 g. For example, the floorboard can further comprise a decorative layer on top of the main panel. For example, the floorboard can further comprise a protective layer as the topmost layer. For example, the protective layer can comprise aluminum oxide.

For example, the main panel can comprise a wood-based material.

For example, the main panel can comprise a wood based material and optionally a resin.

For example, the main panel can be chosen from high density fiberboards, medium density fiberboards, particle board, laminated wood, plywood and Wood Plastic Composite (WPC).

For example, the main panel can consist of at least one polymer.

For example, the main panel can consist essentially of at least one polymer.

For example, the main panel can comprise a stone based material and/or a metal oxide.

For example, the main panel can comprise magnesium oxide.

For example, the main panel can comprise magnesium oxide and optionally a binder.

For example, the main panel can be a magnesium oxide based board.

For example, the main panel can consist essentially of magnesium oxide.

In one embodiment, the floorboard comprising a main panel and a continuous polymer frame perimeterial to the main panel. In another embodiment, the polymer frame comprises a first locking mechanism disposed on two opposing edges of the main panel, and a second locking mechanism different from the first locking mechanism disposed on two other opposing edges of the main panel.

For example, the first locking mechanism can comprise a male portion on one of the two opposing edges and a female counterpart on the other of the two opposing edges. For example, the first locking mechanism can be a tongue and groove mechanism. For example, the first locking mechanism can extend all along two opposing edges of the floorboard. For example, the first locking mechanism can be on the long edges of the floorboard.

For example, the second locking mechanism can comprise a male portion on one of the two opposing edges and a female counterpart on the other of the two opposing edges. For example, the second locking mechanism can be a drop and lock mechanism. For example, the second locking mechanism can extend all along two opposing edges of the floorboard. For example, the second mechanism can be on the short edge of the floorboard.

For example, the main panel can comprise at least one porous surfaces and the polymer frame can fuse or bound thereto.

For example, the polymer frame can comprise a plurality of recesses along at least two of the four edges of the floor board.

For example, the recesses can be along the two opposing edges carrying the tongue and groove mechanism.

For example, the recesses can be dimensioned so as to prevent deformation, warping, cracking and/or bending of the tongue and groove mechanism.

For example, the recesses can be along the two opposing edges carrying the drop and lock mechanism.

For example, the recesses can be dimensioned so as to prevent deformation, warping, cracking and/or bending of the drop and lock mechanism.

For example, the recesses can be along all four of the edges of the floorboard.

For example, the recesses can be dimensioned so as to prevent deformation, warping, cracking and/or bending of the drop and lock mechanism and the tongue and groove mechanism.

For example, the recesses can have a depth having a value of about 15 to about 95% a value of a width of a outermost portion the first locking mechanism and/or second locking mechanism.

For example, the recesses can have a depth having a value of about 25 to about 80% a value of a width of a outermost portion the first locking mechanism and/or second locking mechanism.

For example, the recesses can have a depth having a value of about 50 to about 75% a value of a width of a outermost portion the first locking mechanism and/or second locking mechanism.

For example, the polymer frame can additionally comprise a plurality of recesses along at least two of the four edges of the floor board, such that the polymer frame remains continuous, and that the locking mechanisms remain functional.

For example, the recesses can be along the two opposing edges carrying the tongue and groove mechanism.

For example, the recesses can be along the two opposing edges carrying the drop and lock mechanism.

For example, the recesses can be along all four of the edges of the floorboard.

For example, the floorboard can be made by placing the main panel in a mold carrying the shape of the polymer frame, injecting the mold with polymer and allowing the polymer to cure into the polymer frame.

For example, the recesses on the floorboard can be made by further cutting the polymer frame on the edges containing the recesses.

For example, the process can comprise cutting recesses into the polymer frame at least two opposing edges of the floorboard.

For example, the main panel can be of a rectangular prism shape.

In another embodiment, the main panel itself comprises a locking mechanism along two opposing edges of the main panel. In this embodiment, the main panel comprises a polymer coating that coats at least the locking mechanism.

For example, the polymer coating can coat the entire main panel. For example, the polymer coating can be of thickness of about 1 mm to 5 mm, more specifically about 1 mm to 4 mm.

For example, the main panel can comprise a porous surface and the polymer coating can fuse or bound thereto.

Referring now to FIGS. 1 to 20, therein illustrated is a floorboard 100 with a continuous polymer frame 120. The polymer frame 120 continuously surrounds the main panel 110 of the floorboard 100. The frame 120 cover the whole perimeter of the board. The frame 120 is in other words perimeterially secured to the floorboard 100. Along the opposing long edges 160 and 161, the first locking mechanism 150, optionally a tongue and groove mechanism, is shown, where the male portion 180 (optionally a tongue) is on one edge 160 and the female counterpart 170 (optionally a groove) is on the opposing edge 161. Along the opposing short edges 190 and 191, the second mechanism 151, optionally a drop and lock mechanism, is shown, where the male portion 140 (comprising optionally of protruding polymer blocks) is on one edge 190 and the female counterpart 130 is on the opposing edge 191.

The main panel 110 can have a balance sheet 200 underneath it. The top of the main panel 110 can be hidden underneath a decorative layer 210, which can in turn be covered by a protective layer 220 that provides resistance against wear.

In one embodiment of the present disclosure, as shown in FIG. 7, a floorboard 300 comprises a main panel 310 that comprises a locking mechanism 350 along two opposing edges 360 and 361, where the locking mechanism 350 is coated by a polymer coating 320. A male portion 380 of the locking mechanism 350 is located on one edge 360 and the female counterpart 370 is located on the opposing edge 361.

In one embodiment of the present disclosure, as shown in FIG. 9, the male portion of the drop and lock mechanism can be multiple protruding blocks.

In one embodiment of the present disclosure, as shown in FIG. 10, the male portion of the drop and lock mechanism can be a continuous L-shaped ledge along one of the short edge of the floorboard.

In one embodiment of the present disclosure, as shown in FIGS. 11-14, the floorboard 400 has main panel 410, which comprises a continuous polymer frame 420 perimeterial to the main panel 400. Along the opposing long edges 460 and 461, the first locking mechanism, optionally a tongue and groove mechanism, is shown, where the male portion 480 (optionally a tongue) is on one edge 460 and the female counterpart 470 (optionally a groove) is on one opposing edge 461. Along the opposing short edges 490 and 491, the second mechanism, optionally a drop and lock mechanism, is shown, where the male portion 430 is on one edge 491 and the female counterpart 431 (shown on FIGS. 12 and 14) is on the opposing edge 191. Along the four edges, recesses 421 are shown along the edges 460, 461, and 491 (recesses not visible on edge 490 from top view) in FIG. 11, on edge 461 in FIG. 12, on edge 491 in FIG. 13, and on edge 490 in FIG. 14.

It was observed that the recesses 421 defined in the edges were useful to prevent deformation, warping, cracking and/or bending of the tongue and groove mechanism.

The present disclosure has been described with regard to specific examples. The description was intended to help the understanding of the disclosure, rather than to limit its scope. It will be apparent to one skilled in the art that various modifications can be made to the disclosure without departing from the scope of the disclosure as described herein, and such modifications are intended to be covered by the present document. 

1. A floorboard comprising: a main panel, and a continuous polymer frame perimeterial to the main panel, wherein the polymer frame comprises a first locking mechanism disposed on two opposing edges of the main panel, and a second locking mechanism different from the first locking mechanism disposed on two other opposing edges of the main panel, the first locking mechanism being a tongue and groove mechanism positioned on the long edges of the panel and the second locking mechanism being a drop and lock mechanism positioned on the short edges of the panel.
 2. The floorboard of the claim 1, wherein the first locking mechanism comprises a male portion on one of a first pair of two opposing edges and a female counterpart on the other of the two opposing edges of the first pair.
 3. The floorboard of claim 2, wherein the second locking mechanism comprises a male portion on one of a second pair of two opposing edges and a female counterpart on the other of the two opposing edges of the second pair.
 4. The floorboard of claim 1, wherein the tongue extends all along one of the two opposing edges of the first pair and the groove extends all along the other of the two opposing edges of the first pair.
 5. The floorboard of claim 4, wherein the male portion of the drop and lock mechanism comprises a continuous L-shaped ledge.
 6. The floorboard of claim 4, wherein the male portion of the drop and lock mechanism comprises a multitude of protruding blocks.
 7. The floorboard of claim 1, wherein the polymer frame comprises a plurality of recesses along at least two of the four edges of the floor board.
 8. The floorboard of claim 7, wherein the recesses are along the two opposing edges carrying the tongue and groove mechanism.
 9. The floorboard of claim 7, wherein the recesses are along the two opposing edges carrying the drop and lock mechanism.
 10. The floor board of claim 7, wherein the recesses are along all four of the edges of the floorboard.
 11. The floorboard of claim 7, wherein said recesses have a depth having a value of about 50 to about 75% a value of a width of a outermost portion the first locking mechanism and/or second locking mechanism.
 12. The floorboard of claim 1, wherein the main panel is made of a wood based material and optionally a resin.
 13. The floorboard of claim 1, wherein the main panel comprises a stone based material and/or a metal oxide.
 14. The floorboard of claim 1, wherein the main panel comprises magnesium oxide.
 15. The floorboard of claim 1, wherein the main panel comprises magnesium oxide and optionally a binder.
 16. The floorboard of claim 1, wherein the edges of the main panel comprise porous surfaces and the polymer frame is fused or bound thereto.
 17. The floorboard of claim 1, wherein the main panel is chosen from high density fiberboards, medium density fiberboards, particle board, laminated wood, plywood and Wood Plastic Composite (WPC).
 18. The floorboard of claim 1, wherein the main panel is consists essentially of at least one polymer.
 19. The floorboard of claim 1, wherein the main panel is a magnesium oxide based board.
 20. A process of manufacturing the floorboard of claim 1, the process comprising placing the main panel in a mold carrying the shape of the continuous polymer frame, and the first and the second locking mechanisms; injecting a polymer within the mold under conditions effective for bonding or fusing the polymer to the edges of the main panel; and allowing the polymer to cure and form the polymer frame. 